Investigations on the thermal workpiece distortion in MQL deep hole drilling of an aluminium cast alloy

Biermann, Dirk; Iovkov, Ivan

doi:10.1016/j.cirp.2015.04.072

Cited by 31 publications

(7 citation statements)

References 16 publications

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“…In the research of straightness deviation control methods, Matsuzaki et al (Matsuzaki et al, 2015) designed a new tool that can suppress chattering to improve the straightness of the deep hole. Biermann et al (Biermann and iovkov, 2015) Pointed out that the tapered guide chamfer of the single-lip gun drill would cause the straightness deviation, based on which they proposed a radial spindle compensation method and experimentally demonstrated the effectiveness of the method. Zhang et al (Zhang et al, 2018) designed a customized tool regrinding system that makes it possible to obtain high-quality tools with precisely controlled geometry to improve the straightness of the deep hole.…”

Section: Introductionmentioning

confidence: 99%

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

Zhu

Zhang

Li³

et al. 2021

JAMDSM

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Nickel-based superalloys also have super high strength at high temperatures, which are typically difficult to be processed. As the material of hydraulic parts, aircraft engines, and downhole intelligent tools, it has the characteristics of large cutting deformation, severe work hardening, and low thermal conductivity in deep hole machining, which will lead to the problem of poor straightness of the deep hole. In order to solve the problem of poor straightness of the deep hole in machining nickel-based superalloys, a three-dimensional finite element model of BTA deep hole drilling based on thermal-mechanical coupling is established, and the influence of different blade angles, rotation speeds, and feed rates on drilling force is calculated. The prediction model of drilling force is obtained based on the response surface regression analysis method, and the multi-objective optimization of blade angle, rotation speed, and feed rate are carried out by using the random direction search method. The BTA deep hole drilling experiments are carried out by using the optimized tool and process parameters, and the effects of different process parameters on the straightness of the deep hole of nickel-based superalloys are analyzed. The results of the research show that: Different rotation speeds and feed rates will lead to different degrees of strain hardening and thermal softening. This will lead to a significant difference in the value of the drilling force on the tool. The straightness deviation of the deep hole in nickel-based superalloys can be controlled by optimizing the tool structure and process parameters. The research work in this paper can provide a basis for the structural design of the BTA tool and optimization of process parameters.

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Section: Introductionmentioning

confidence: 99%

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

Zhu

Zhang

Li³

et al. 2021

JAMDSM

View full text Add to dashboard Cite

show abstract

“…The reasons for the hole straightness deviation are still poorly understood due to the lack of knowledge on the exact drilling mechanism inside the hole. It could be attributable to the variability in the workpiece material hardness and yield strength; misalignment of the apex between the preceding and succeeding drills; variation in the inner and outer cutting edges arising from the resharpening process [2]; misalignment in drill shafts, inadequate stiffness of the drill stem, poor cutting edge preparation [3]; rapid degradation and premature breakage of the carbide cutting edges [4]; poor selection of the drilling parameters, including speed, feed rate and coolant pressure and flow rate [5,6]. Since the tool shaft in deep hole drilling is extraordinarily long, an initial study revealed that the influence of its dynamics on the drilling process may not be neglected [7].…”

Section: Introductionmentioning

confidence: 99%

RETRACTED ARTICLE: Effects of multi-support misalignments on hole straightness predict model in deep hole drilling

Xue

et al. 2020

J Braz. Soc. Mech. Sci. Eng.

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Straightness is one of the key technical indicators for deep hole gun drilling. This work studies the effect of drill shaft support misalignment on hole straightness in relation to various control factors. Misalignments occur in machine spindles, intermediate supports and pilot bushings. A predictive hole straightness deviation model for multi-support deep hole drilling process is introduced using the Euler column theory. The model considers the effect of the misalignment of whip guides in addition to the effects of the varying distance among the supports. The model also takes into account the effects of the thrust force and the drill lengths. Through simulation, this work analyzes the effect of each control factor on the results and optimizes the setting for each control factor. Further experiments on Ti6Al4V alloy then verify these estimates. Through research, fixed support at chip box has a greater influence on straightness deviation as compared to the misalignment at other supports; the distance between supports nearer to the chip box has more control on straightness deviation as compared to the other support distances.

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“…In fact, this bonding is responsible for premature wear of the cutting tool for the poor surface finish of the hole and the variations in the diameter of the hole. Several authors showed at low cutting speeds (up to 25 m/min) bonding of aluminium occurring at the rake face and at the main cutting edges [23][24][25][26]. Because of the high adhesion affinity of the aluminium alloy with the drill tool, high feed was used during deep hole drilling of aluminium alloy using MQL (Minimum quantity lubrication) [24].…”

Section: Introductionmentioning

confidence: 99%

“…Several authors showed at low cutting speeds (up to 25 m/min) bonding of aluminium occurring at the rake face and at the main cutting edges [23][24][25][26]. Because of the high adhesion affinity of the aluminium alloy with the drill tool, high feed was used during deep hole drilling of aluminium alloy using MQL (Minimum quantity lubrication) [24]. To improve the drilling quality and efficiency of machining, aluminium alloy nano-coated drills were used [25].…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical analysis on drilling of carbon fibre reinforced plastic and aluminium stacks

Zitoune

Krishnaraj

Collombet

et al. 2016

Composite Structures

105

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In this paper, experimental and numerical study of drilling of carbon fibre reinforced plastic (CFRP) laminate with aluminium alloy stacks has been carried out. Drilling of these multi-materials is a challenging task to manufacturing engineers because of different mechanical properties of materials. In this work, the impact of the machining parameters on the effect of twist drill and the geometry of double cone drill on cutting forces, holes quality and on CFRP/Al interface have been investigated. From the experimental study, it was found that the double cone drills induce less thrust force compared to the standard twist drill. From the numerical analysis based on the linear fracture mechanics of the CFRP and the plastic behaviour of the aluminium with isotropic hardening, on the one hand, the critical thrust force responsible for the delamination of the last ply as a function of the aluminium thickness has been identified and on the other hand, the maximum thrust force responsible for the interface separation of CFRP/Al has been predicted as a function of the aluminium thickness.

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Investigations on the thermal workpiece distortion in MQL deep hole drilling of an aluminium cast alloy

Cited by 31 publications

References 16 publications

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

Retraction: Study on straightness deviation control in the BTA deep hole drilling based on thermal-mechanical coupling simulation method

RETRACTED ARTICLE: Effects of multi-support misalignments on hole straightness predict model in deep hole drilling

Experimental and numerical analysis on drilling of carbon fibre reinforced plastic and aluminium stacks

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